Mechanical locking of floor panels with a flexible tongue

ABSTRACT

Floor panels which are provided with a mechanical locking system including an extruded flexible tongue in a sidewardly open groove which during a vertical folding motion is bent horizontally. A tongue adapted for being received in a sidewardly open groove of a floor panel, wherein the tongue, which is an elongated extruded section, when received in the groove is bendable in a plane substantially parallel with a front face of the floor panel, such that the tongue is at least partially resiliently displaceable inside said sidewardly open groove in said plane during locking of the floor panel with another floor panel and wherein a vertical protrusion, serving as a friction connection between the tongue and the groove, is arranged at an upper or lower part of the tongue, wherein the tongue has a length in the longitudinal direction of the tongue and a total width perpendicular to the length, and the total width varies in the longitudinal direction of the tongue.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.13/670,039, filed on Nov. 6, 2012, which is a continuation of U.S.application Ser. No. 12/216,892, filed on Jul. 11, 2008, which is acontinuation of U.S. application Ser. No. 11/575,600, filed on Dec. 7,2007, which is a national stage application of International ApplicationNo. PCT/SE2005/001586, which claims priority to European Application No.04025167.0, filed on Oct. 22, 2004. The entire contents of each of U.S.application Ser. No. 13/670,039, U.S. application Ser. No. 12/216,892,U.S. application Ser. No. 11/575,600, International Application No.PCT/SE2005/001586, and European Application No. 04025167.0 are herebyincorporated herein by reference.

TECHNICAL FIELD

The invention generally relates to the field of floor panels withmechanical locking systems and such building panels that are made of aboard material. The invention relates to tongues for such lockingsystems and methods for providing and installing panels with suchlocking systems.

FIELD OF APPLICATION OF THE INVENTION

The present invention is particularly suitable for use in floatingfloors, which are formed of floor panels which are joined mechanicallywith a locking system integrated with the floor panel, i.e. mounted atthe factory, are made up of one or more upper layers of veneer,decorative laminate or decorative plastic material, an intermediate coreof wood-fibre-based material or plastic material and preferably a lowerbalancing layer on the rear side of the core. The following descriptionof prior-art technique, problems of known systems and objects andfeatures of the invention will therefore, as a non-restrictive example,be aimed above all at this field of application and in particularlaminate flooring formed as rectangular floor panels with long andshorts sides intended to be mechanically joined on both long and shortsides. The long and shorts sides are mainly used to simplify thedescription of the invention. The panels could be square, the sidescould have an angle other than 90 degree and they could have more than 4sides. It should be emphasized that the invention can be used in anyfloor panel and it could be combined with all types of known lockingsystem, on an adjacent side of the same panel, where the floor panelsare intended to be joined using a mechanical locking system in thehorizontal and vertical directions. The invention can thus also beapplicable to, for instance, solid wooden floors, parquet floors with acore of wood or wood-fibre-based material and a surface of wood or woodveneer and the like, floors with a printed and preferably also varnishedsurface, floors with a surface layer of plastic or cork, linoleum,rubber. Even floors with hard surfaces and or core materials such asstone, tile, glass and similar are included as well as floorings withsoft wear layer, for instance needle felt glued to a board. With diamondtools it is possible to form one piece angling system on for instance along side of a hard material, such as marble, ceramics, glass or similarmaterials. In a similar way locking system could also be formed in solidmetal plates and other types of non-flexible composite boards, all suchembodiments could have a flex tongue on long or short side, according tothe basic principle of the invention. The invention can also be used forjoining building panels which preferably contain a board material forinstance wall panels, ceilings, furniture components and similar.

BACKGROUND OF THE INVENTION

Laminate flooring usually consists of a core of a 6-12 mm fibre board, a0.2-0.8 mm thick upper decorative surface layer of laminate and a0.1-0.6 mm thick lower balancing layer of laminate, plastic, paper orlike material. The surface layer provides appearance and durability tothe floor panels. The core provides stability, and the balancing layerkeeps the panel plane when the relative humidity (RH) varies during theyear. The floor panels are laid floating, i.e. without gluing, on anexisting sub floor. Laminate flooring and also many other types offlooring are made by the surface layer and the balancing layer beingapplied to a core material. This application may take place by gluing apreviously manufactured decorative layer, for instance when the fibreboard is provided with a decorative high pressure laminate which is madein a separate operation where a plurality of impregnated sheets of paperare compressed under high pressure and at a high temperature. Thecurrently most common method when making laminate flooring, however, isdirect laminating which is based on a more modern principle where bothmanufacture of the decorative laminate layer and the bonding to thefibre board take place in one and the same manufacturing step.Impregnated sheets of paper are applied directly to the panel andpressed together under pressure and heat without any gluing.

Traditional hard floor panels in floating flooring of this type areusually joined by means of glued tongue-and-groove joints.

In addition to such traditional floors, which are joined by means ofglued tongue-and-groove joints, floor panels have recently beendeveloped which do not require the use of glue and instead are joinedmechanically by means of so-called mechanical locking systems. Thesesystems comprise locking means, which lock the panels horizontally andvertically. The mechanical locking systems are usually formed bymachining of the core of the panel. Alternatively, parts of the lockingsystem can be formed of a separate material, for instance aluminium orHDF, which is integrated with the floor panel, i.e. joined with thefloor panel in connection with the manufacture thereof.

The main advantages of floating floors with mechanical locking systemsare that they can easily and quickly be laid by various combinations ofinward angling, snapping-in and insertion. They can also easily be takenup again and used once more at a different location. A further advantageof the mechanical locking systems is that the joint edges of the floorpanels can be made of materials, which need not to have good gluingproperties. The most common core material is fibreboard with highdensity and good stability usually called HDF—High Density Fibreboard.Sometimes also MDF—Medium Density Fibreboard—is used as core.

DEFINITION OF SOME TERMS

In the following text, the visible surface of the installed floor panelis called “front side”, while the opposite side of the floor panel,facing the sub floor, is called “rear side”. The edge between the frontand rear side is called “joint edge”. By “horizontal plane” is meant aplane, which extends parallel to the outer part of the surface layer.Immediately juxtaposed upper parts of two adjacent joint edges of twojoined floor panels together define a “vertical plane” perpendicular tothe horizontal plane.

By “joint” or “locking system” are meant co acting connecting means,which connect the floor panels vertically and/or horizontally. By“mechanical locking system” is meant that joining can take place withoutglue. Mechanical locking systems can in many cases also be combined withgluing. By “integrated with” means formed in one piece with the panel orfactory connected to the panel.

By a “flexible tongue” is meant a separate tongue which has a lengthdirection along the joint edges and which is forming a part of thevertical locking system and could be displaced horizontally duringlocking. The tongue could be for example flexible and resilient in sucha way that it can bend along its length and spring back to its initialposition.

By “flexible tongue blank” are meant two or more flexible tongues, whichare connected to a one-piece component. Examples of such flexible tongueblanks will be described in more detail below.

By “fixing the flexible tongue” is meant that the flexible tongue shouldat least be sufficiently attached to the floor panel so as not toincidentally fall off during handling of the floor panel, at thefactory, during transport and/or in installation. By “mechanicallyfixed” is meant that the fixing is essentially due to shape or frictionforce.

By “angling” is meant a connection that occurs by a turning motion,during which an angular change occurs between two parts that are beingconnected, or disconnected. When angling relates to connection of twofloor panels, the angular motion takes place with the upper parts ofjoint edges at least partly being in contact with each other, during atleast part of the motion.

By “vertical folding” is meant a connection of three panels where afirst and second panel are in a connected state and where an anglingaction connects two perpendicular edges of a new panel to the first andsecond panel. Such a connection takes place for example when a long sideof first panel in a first row is already connected to a long side of asecond panel in a second row. The third panel is than connected byangling to the long side of the first panel in the first row. Thisspecific type of angling action, which also connects the short side ofthe new panel and second panel, is referred to as vertical folding

PRIOR-ART TECHNIQUE AND PROBLEMS THEREOF

For mechanical joining of long sides as well as short sides in thevertical and horizontal direction (direction D1, D2) several methods areused but the locking is always performed in 3 steps where angling orsnapping are combined with displacement along the joint edge in thelocked position after an optional side has been joined.

-   -   Angling of long side, displacement and snapping-in of short side    -   Snapping-in of long side, displacement and snapping-in of short        side.    -   Angling of short side, displacement of the new panel along the        short side edge of the previous panel and finally downward        angling of two panels.

These laying methods can also be combined with insertion along the jointedge.

It is known that the locking system may, however, be formed so thatsnapping-in may occur by a motion which is vertical to the surface ofthe floor panel. Generally, the long side is locked by angling and theshort side with a vertical angling which locks with a snap action. Sucha system in described in WO 01/02669 (Akzenta). The connection of panelsis complicated and difficult since fibres must be compressed and ahammer with a tapping block must be used. The panels are locked invertical direction mainly by a friction force and the locking strengthis low.

It is known that floor panels may be locked on long and short sidevertically and horizontally with one simple vertical folding action (WO03/083234 Applicant Välinge Aluminium). This document comprises a partof this application. The object of WO 03/083234 is to provide a jointsystem and floor panels which can be laid with a vertical folding.

A floor panel with a vertical joint in the form of a flexible tongue anda groove is provided, the tongue being made of a separate material andbeing flexible so that at least one of the sides of the floor panel canbe joined by a vertical motion parallel to the vertical plane.

This document also show how a joint system can be made with a flexiblespring tongue which can be displaced and/or compressed horizontally inand out or alternatively be bent vertically up or down. It describes aseparate tongue of, for instance, wood fibre material, which can bedisplaced horizontally by means of a flexible material, for instance arubber paste. It also describes an embodiment with a tongue, which hasan inner part that is resilient.

This known technology with a tongue, which during locking moveshorizontally in relation to the adjacent edges, offers severaladvantages over the known installation methods. The locking is easy andfaster since 3 steps are reduced to one step.

The invention described in WO 03/083234 does not however show the bestmode of locking floor panels with a vertical folding. The productioncost and the locking function could be improved considerably.

BRIEF DESCRIPTION OF THE INVENTION AND OBJECTS THEREOF

A first overall objective of the present invention is to provide alocking system based on a vertical folding with a flexible tongue fixedin a tongue groove. The locking system should make it possible to lockall four sides of one panel vertically and horizontally to other panelswith angling action only. The costs and functions should be favorablecompared to the known technology. An essential part of the overallobjective is to improve the function and costs of those parts of thelocking system that causes the flexible tongue to displace duringlocking and spring back in locked position.

More specifically the object is to provide a vertical folding lockingsystem with a flexible tongue where one or several of the followingadvantages are obtained.

The flexible tongue should preferably be possible to displace duringlocking with such a low force that no tools will be needed in connectionwith installation.

The spring effect should be reliable and the flexible tongue should moveback, partly or completely, to a pre-determined position when the panelshave been brought to the position where they are to be locked.

The vertical locking should be strong and prevent that two locked panelswill move vertically when humidity is changing or when people walk on afloor.

The locking system should be able to lock floor panels vertically withhigh precision so that the surfaces are essentially in the same plane.

The vertical locking system should be designed in such a way that thematerial and production costs could be low.

The separate flexible tongue should be possible to fix to the floorpanel in a simple and cost effective way. The fixing should keep theflexible tongue at least fixed to the panel during production, transportand installation.

A second objective is to provide methods to produce the flexible tongueand flexible tongue blanks which are later to constitute parts of themechanical locking system of the floor panels.

A third object is to provide a rational method for fixing the flexibletongues with the joint portion of the floor panel to form an integratedmechanical locking system where the flexible tongue is factory fixed tothe floor panel.

A fourth object is to provide installation methods to connect floorpanels with vertical folding.

A fifth object is to provide a tool and a method to take up the floorpanels.

The above objects of the invention are achieved wholly or partly by alocking system, floor panels, a flexible tongue, a flexible tongue blankand production and installation methods according to the independentclaims. Embodiments of the invention are evident from the dependentclaims and from the description and drawings.

Although it is an advantage to integrate the flexible tongue with thepanel in the factory before installation, the invention does not excludean embodiment in which flexible tongues are delivered as separatecomponents to be fixed to the panel by the installer prior toinstallation, the invention does not exclude glue, sealing compounds,wax or other similar chemicals in the locking system.

According to a first aspect of the invention, a new floor panelcomprising connecting means, which are integrated with the floor paneland adapted to connect the new floor panel with an essentially identicalfirst and second floor panel is provided.

The upper joint edges of said new and second floor panels define in theconnected state a vertical plane.

The connecting means are designed to connect said new floor panel withsaid second floor panel in a horizontal direction perpendicular to saidvertical plane and in a vertical direction parallel to the verticalplane. The vertical connection comprising a flexible tongue in adisplacement groove, in one of the new or the second floor panels. Thedisplacement groove is formed in the edge of the panel and is opentowards the vertical plane. The flexible tongue has a length directionalong the joint edges, a width in the horizontal plane perpendicular tothe length and a thickness in the vertical direction.

The flexible tongue is designed to cooperate, in said connected statewith a tongue groove of another one of the new or second floor panels.

The horizontal connection comprising a locking strip which projects fromsaid vertical plane and carries a locking element 8 in the second panel.

The locking strip 6 is designed to cooperate, in said connected state,with a downward open locking groove of the new floor panel. The newfloor panel could be locked to the first and second floor panel withvertical folding. The flexible tongue is during the vertical foldingdisplaced two times in the displacement groove. The first displacementis effected by the vertical folding of the new floor panel whereby atleast a part of the flexible tongue is bent in the length direction andparallel with the width.

A second displacement of the flexible tongue towards its initialposition is accomplished substantially by a spring effect caused by saidbending of said flexible tongue.

According to a first aspect of the second objective a tongue blank isprovided consisting of several flexible tongues connected to each other.This facilitated automatic handling of the tongues in connection withthe fixing of the flexible tongues into the displacement groove. In analternative embodiment, separate tongues are produced, which arepreferably moved by means of vibration to a pre-determined positioned,where the tongue is displaced into and fixed in the displacement groove

According to a first aspect of the third objective a production methodis provided to fix the flexible tongue in the displacement groove. Theflexible tongue is separated from a tongue blank and displacedessentially parallel to its width or length into the displacement groovewhere it is fixed with a friction force.

According to a first aspect of the fourth objective installation methodsare provided which make it possible to connect floor panels verticallyand horizontally long side to short side with a simple angling motion.

According to a second aspect, there is provided a floor panel having anedge portion presenting a sidewardly open groove, in which a tongueformed as a separate part is received. The tongue is bendable in a planesubstantially parallel with a main plane of the floor panel, such thatthe tongue is resiliently displaceable in said plane.

According to a third aspect, there is provided a tongue adapted forbeing received in a sidewardly open groove of a floor panel. The tongue,when received in the groove, is bendable in a plane substantiallyparallel with a main plane of the floor panel, such that the tongue isat least partially resiliently displaceable in said plane.

According to a first aspect of the fifth objective a reinstallation toolto take up installed floor panels with a flexible tongue is provide. Thetool is inserted into a tongue groove or a displacement groove of aninstalled panel and the tongue is pulled or pushed out of the tonguegroove.

According to a second aspect of the fifth objective methods to take upinstalled floor panels with a flexible tongue are provided. One methodcomprising removing of a tongue from a first edge of an installed floorpanel, preferably using the reinstallation tool, and preferably angle upthe floor panel along a second edge. One advantage is that lastinstalled floor panel in one row could be angle up, while the otherfloor panels in the same row are laying flat on the subfloor in aconnected state to a previously installed row. This method to take up afloor panel reduces considerably the risk of damaging the lockingsystem, especially if the floorboards are thick and heavy or installed atight fit. Further methods is to use the conventional methods adopted totaking up floor panels with a conventional non flexible tongue, e.g.angling-angling, angling-sliding, snapping-sliding or snapping-angling.In such traditional methods, generally the whole row has to be angledup.

The invention allows horizontal and vertical locking of all sides offloor panels with a simple angling of the long sides only. Therefore itis especially suited for use in floor panels which are difficult todisplace in locked position for example because they are long, in panelswhere parts of the locking system is made of a material with highfriction, such as wood and in locking systems which are produced withtight fit, without play or even with pretension. Especially panels withsuch pretension where the locking strip is bent in locked position andpresses the panels together are very difficult to displace. A lockingsystem that allows a vertical folding according to the invention willdecrease the installation time of such panels considerably.

The invention is also especially well-suited for panels which areconnected long side to short side and for panels which are wide forexample with a width larger than 20 cm. Such panels are difficult tosnap on short side and in most materials they must have a verticallocking to avoid height differences between the joint surfaces. Theinvention could preferably be combined with bevels or similar edgeconfigurations on short and/or long sides. In such a floor, a simple andlow cost embodiment of the flexible tongue, could be used, since heightdifferences of adjacent edges preferably short side edges, will be lessvisible.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1a-1d illustrate one embodiment of a locking system according tothe invention.

FIGS. 2a-2e illustrate in different steps mechanical joining of a floorpanels according to the invention.

FIGS. 3a-3b show floor panels with a mechanical locking system on ashort side.

FIGS. 4a-4b show the flexible tongue during the locking action.

FIGS. 5a-5b show how short sides of two floor panels could be lockedwith vertical folding.

FIGS. 6a-6c show another embodiment of the invention.

FIGS. 7a-7f show different embodiments of a flexible tongue.

FIGS. 8a-8d show schematically how a flexible tongue could be separated,positioned and fixed to a floor panel.

FIGS. 9a-9d show schematically how a flexible tongue could be separated,positioned and fixed to a floor panel.

FIGS. 10a-10e show schematically how a separate flexible tongue could bepositioned and fixed to a floor panel.

FIGS. 11a-11c show schematically how a separate flexible tongue could bedisplaced into a displacement groove of a floor panel.

FIGS. 12a-12c show schematically how two separate flexible tongues couldbe displaced, at the same time, into the displacement groove of a floorpanel.

FIGS. 13a-13f show schematically different embodiments according to theinvention.

FIGS. 14a-14d show how two types of panels could be locked verticallyand horizontally long side to short side with a simple angling actiononly.

FIGS. 15a-15d show another embodiment according to the principles inFIG. 10a -d.

FIGS. 16a-16f show square panels and alternative locking methods.

FIGS. 17a-17d show how widely used traditional panels could be adjustedto vertical folding.

FIG. 18 shows the flexible tongue in another embodiment according to theinvention.

FIGS. 18a-18c show the flexible tongue in another embodiment accordingto the invention.

FIGS. 18d-18f show embodiments for a split floor panel.

FIGS. 19a-19c show embodiments of the flexible tongue with variousshapes of indentations

FIG. 19d shows an embodiment for compensating for production tolerancesof the flexible tongue

FIGS. 20a-20d show embodiments with different lengths and numbers of theflex tongue

FIGS. 21a-21d show another embodiment with a displacement groove, whichis not continuous over the whole edge

FIGS. 22a-22d various embodiments of the tongue blank and separateflexible tongues

FIGS. 23a-23g show the flexible tongue in combination with differentembodiments of the displacement groove, the locking strip, the lockinggroove and the lower contact surface of locking groove panel.

FIGS. 24a-24g show different embodiments of a dismounting tool anddismounting methods.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

A first preferred embodiment of a floor panel 1, 1′ provided with amechanical locking system according to the invention is now describedwith reference to FIGS. 1a-1d . To facilitate understanding, the lockingsystems in all figures are shown schematically. It should be emphasizedthat improved or different functions can be achieved using combinationsof the preferred embodiments. The inventor has tested all known andespecially all commercially used locking systems on the market in alltype of floor panels, especially laminate and wood floorings and theconclusion is that at least all these known locking systems which haveone or more tongues could be adjusted to a system with one or moreflexible tongues according to the invention. Most of them could easilybe adjusted in such a way that they will be compatible with the presentsystems. Several flexible tongues could be located in both adjacentedges, one over the other and they could be on different levels in thesame edge or installed in the same groove after each other. The flexibletongue could be on long and/or short sides and one long or short sidecould be combined with a flexible tongue on another long or short side,which could have all known locking systems, preferably locking systemswhich could be locked by angling or a vertical movement. The inventiondoes not exclude floor panels with flexible tongues on for example along and a short side. Such panels could be installed by a verticalmotion without any angling. Angles, dimensions, rounded parts etc. areonly examples and could be adjusted within the principles of theinvention.

A first preferred embodiment of a floor panel 1, 1′ provided with amechanical locking system according to the invention is now describedwith reference to FIGS. 1a -1 d.

FIG. 1a illustrates schematically a cross-section of a joint between ashort side joint edge 4 a of a panel 1 and an opposite short side jointedge 4 b of a second panel 1′.

The front sides 61 of the panels are essentially positioned in a commonhorizontal plane HP, and the upper parts 21, 41 of the joint edges 4 a,4 b abut against each other in a vertical plane VP. The mechanicallocking system provides locking of the panels relative to each other inthe vertical direction D1 as well as the horizontal direction D2.

To provide joining of the two joint edges in the D1 and D2 directions,the edges of the floor panel have in a manner known per se a lockingstrip 6 with a locking element 8 in one joint edge, hereafter referredto as the “strip panel” which cooperates with a locking groove 14 in theother joint edge, hereafter referred to as the “fold panel”, andprovides the horizontal locking.

The mechanical locking system according to the invention comprises aseparate flexible tongue 30 fixed into a displacement groove 40 formedin one of the joint edges. The flexible tongue 30 has a groove portionP1, which is located in the displacement groove 40 and a projectingportion P2 projecting outside the displacement groove 40. The projectingportion P2 of the flexible tongue 30 in one of the joint edgescooperates with a tongue groove formed in the other joint edge.

In this embodiment, the panel 1 could for example have a body or core 60of wood-fibre-based material such as HDF, plywood or solid wood.

The flexible tongue 30 has a protruding part P2 with a rounded outerpart 31 and a sliding surface 32, which in this embodiment if formedlike a bevel. It has upper 33 and lower 35 tongue displacement surfacesand an inner part 34.

The displacement groove 40 has an upper 42 and a lower 46 opening, whichin this embodiment are rounded, a bottom 44 and upper 43 and lower 45groove displacement surfaces, which preferably are essentially parallelwith the horizontal plane HP.

The tongue groove 20 has a tongue-locking surface 22, which cooperateswith the flexible tongue 30 and locks the joint edges in a verticaldirection D1. The fold panel 1′ has a vertical locking surface 24, whichis closer to the rear side 62 than the tongue groove 20. The verticallocking surface 24 cooperates with the strip 6 and locks the joint edgesin another vertical direction. The fold panel has in this embodiment asliding surface 23 which cooperated during locking with the slidingsurface 32 of the tongue. Preferably there are spaces of 0.1 mm or morebetween all surfaces, which are not active in the vertical or horizontallocking as shown in FIG. 1, especially between inner and upper part ofthe tongue groove 20 and the flexible tongue 30.

FIGS. 2a-2e shows how a fold panel 1′ could be locked to a strip panel1. The figures show a vertical motion of two panels towards each other.The figures also shows a part of a vertical folding connecting threepanels to each other as shown in FIG. 5a . The FIGS. 2a-2e shows how thetwo cross sections A-A and A′-A′ of FIG. 5a will be connected when thefold panel 1′ will be angled towards the strip panel 1. FIGS. 2b-c showhow the sliding surfaces cooperate when the folding panel 1′ is movedvertically towards the strip panel 1. The flexible tongue 30 isdisplaced with a first displacement essentially horizontally in thedisplacement groove 40 towards the bottom 44. When the panels are in theposition where they are to be locked to each other, the flexible tongue30 springs back with a second displacement towards its initial positionand the panels are locked vertically between the vertical lockingsurface 24 and the strip 6 and the lower displacement surface 35 and thetongue locking surface 22.

The flexible tongue 30 should preferably be fixed to the displacementgroove 40 with high precision. Depending on the compressibility andfriction between the flexible tongue 30 and the displacement groove 40,the tongue as whole or different parts could be fixed with a small play,for example 0.01-0.10 mm, a precise fit or a pre tension. Wax or otherfriction reducing materials or chemicals could be applied between theflexible tongue and the displacement groove and/or in the tongue grooveand/or in the locking system in order to facilitate displacement of thetongue and the locking and/or to facilitate the fixing of the flexibletongue in the displacement groove.

Even with a play, a precise fit between the upper joint edges could beaccomplished. The lower tongue displacement surface 35 could be formedto press the tongue locking surface 22 and the vertical locking surface24 towards the strip 6. For example the protruding part P2 of the tonguedisplacement surface 35 could be formed with a small angle to thehorizontal plane HP. The protruding part P2 of the flexible tongue willtilt towards the front side 61 and a part of the upper tonguedisplacement surface 33 will press against the upper groove displacementsurface 43 while parts of lower displacement surfaces 35,45 close to thebottom 44 of the displacement groove 40 will press against each other.In such an embodiment, the vertical fit between the upper joint edgeswill mainly depend on the production tolerances between the verticallocking surfaces 24 and a vertical contact surface 6′, in thisembodiment located on the upper part of the strip 6, which in lockedposition, will be in contact with each other and preferably pressagainst each other. The flexible tongue 30 could be formed to cause apermanent pressure force horizontally in the locked position. This meansthat the flexible tongue 30 will only partly spring back to the initialposition. The flexible tongue 30 could optionally be designed with suchdimensions that in locked position it will move slightly towards itsinitial position when people walk on the floor or when the panels atwarping in different humidity. Gradually a perfect vertical connectionwill be accomplished.

FIG. 3a shows a cross section A-A of a panel according to FIG. 3b seenfrom above. The flexible tongue 30 has a length L along the joint edge,a width W parallel to the horizontal plane and perpendicular to thelength L and a thickness T in the vertical direction D1. The sum of thelargest groove portion P1 and the largest protruding part P2 is thetotal width TW. The flexible tongue has also in this embodiment a middlesection MS and two edge sections ES adjacent to the middle section. Thesize of the protruding part P2 and the groove portion P1 varies in thisembodiment along the length L and the tongue is spaced from the twocorner sections 9 a and 9 b. This shape is favorable in order tofacilitate the first and the second displacement of the flexible tongue30.

FIGS. 4a and 4b show the position of the flexible tongue 30 after thefirst displacement towards the bottom 44 of the displacement groove 40.The displacement is caused essentially by bending of parts of theflexible tongue 30 in its length direction L parallel to the width W.This feature is essential for this embodiment of the invention andoffers several advantages

A first important advantage is that the tongue could be made of ratherrigid material, which is strong and stable in the vertical directionwhile at the same time flexible in the horizontal direction D2 ispossible to accomplish. The bending portions could be made considerablylarger than the horizontal displacement needed to accomplish thelocking.

A second advantage is that the parts, which are flexible and facilitatesthe first and second horizontal displacement also supports the verticalstability of the tongue. The advantage is that the total width TW of theflexible tongue and the depth of the displacement groove could be ratherlimited. This improves the strength and moisture deformation of thejoint edge. As a non-restrictive example it could be mentioned that thetotal width TW of the flexible tongue could be about 5-15 mm

A third advantage is that the flexible tongue could be made in one pieceof a single material without any soft and compressible materials. Thiswill decrease the production cost and facilitate the fixing of thetongue in the displacement groove.

The sliding grove is in this preferred embodiment a continuous grooveover the whole length of the join edge. The displacement groove (40)could however be formed in only a part of the edge and it does not haveto be parallel with the edge. The displacement groove (40) could forinstance be curved. Such a groove is easy to produce with a rotatingtool, which could move against the edge.

The fold panel could be disconnected with a needle shaped tool, whichcould be inserted from the corner section 9 b into the tongue grove 20and press the flexible tongue back into the displacement groove 40. Thefold panel could then be angled up while the strip panel is still on thesub floor. Of course the panels could also be disconnected in thetraditional way.

FIGS. 5a and 5b show one embodiment of a vertical folding. A first panel1″ in a first row is connected to a second 1 panel in a second row. Thenew panel 1′ is connected with its long side 5 a to the long side 5 b ofthe first panel with angling. This angling action also connects theshort side 4 b of the new pane with the short side 4 a of the secondpanel. The fold panel 1′ is locked to the strip panel 1 with a combinedvertical and turning motion along the vertical plane VP. The protrudingpart P2 has a rounded and or angled folding part P2′ which duringfolding cooperates with the sliding surface 23 of the folding panel 1′.The combined effect of a folding part P2′, and a sliding surface 32 ofthe tongue which during the folding cooperates with the sliding surface23 of the fold panel 1′ facilitates considerably the first displacementof the flexible tongue 30. The horizontal pressing force could be spreadover a much larger portion than the thickness T of the flexible tongueand the fold panel could easily be folded down with a low force even ifthe spring effect of the bending is high. As a non-restrictive exampleit could be mentioned that a vertical pressing force of 10 N against apiece, which has a length of 100 mm along the long side, applied on thelong side 5 b of the fold panel, as shown in FIG. 5a , could displace aprojecting portion P2 to the inner position even if the spring force is20 N. Most of the pressure force will be horizontal and the flexibletongue will be displaced into the displacement groove 40 without anyrisk of a block effect caused by friction or a tilting and/or verticallybending of the flexible tongue 30. It is an advantage if the lockingsystem is designed in such a way that the locking element 8 is partly inthe locking groove 14 when the first displacement starts. This is shownin FIG. 5b . The top edges 41,21 are partly in contact with each otherand the fold panel 1′ is in the correct starting position. The lockingelement 8 and the locking groove 14 prevent the strip panel 1 and thefold panel 1′ to separate when the flexible tongue 30 is pressed intothe displacement groove 40. En essential feature of this embodiment isthe position of the projecting portion P2, which is spaced from thecorner section 9 a and 9 b. The spacing should be preferably at least10% of the length of the joint edge, in this case the visible short side4 a. FIG. 5a shows that the spacing from the both corner section 9 a and9 b gives the flexibility that the fold panel could during the verticalfolding be connected to the long side of the first panel 1″ with thetongue side 5 a or the strip side 5 b

FIG. 6a-6b show that the flexible tongue could be in the edge of thefold panel 1′. The sliding surface 32 of the tongue cooperates in thisembodiment with the top edge of the strip panel. Thanks to the foldingpart P2′, the locking could be made without any risk of damaging the topsurface layer at the edge. The advantage of this embodiment is that ashort side with a flexible tongue could be connected to a traditionallong side or short side locking system with a strip 6 and a tonguegroove 20 in the same edge.

FIG. 6c shows an embodiment where the displacement groove 40 is notparallel with the horizontal plane HP. This facilitates the connectionof the flexible tongue 30 into the displacement groove 40. Theprotruding part of the flexible tongue 30 is wedge shaped in order topress the vertical contact surface 6′ and the vertical locking surface24 against each other. The locking surfaces between the locking element8 and the locking groove 14 are angled and have an angle which is lessthan 90 degree against the horizontal plane HP and the locking systemcould be connected with a tight fit and/or pre tension.

FIGS. 7a-7e show different embodiments of the flexible tongue 30. InFIG. 7a the flexible tongue 30 has on one of the edge sections afriction connection 36 which could be shaped for instance as a localsmall vertical protrusion. This friction connection keeps the flexibletongue in the displacement groove 40 during installation, or duringproduction, packaging and transport, if the flexible tongue isintegrated with the floor panel at the factory. FIG. 4b shows that thefriction connection 36 keeps one edge section ES essentially still whilethe other edge section ES' moves along the edge. The length L′ in theinner position is in this embodiment larger than the length L in lockedposition.

FIG. 7b shows a tongue blank 50 consisting of several flexible tongues30 connected to each other. In this embodiment the flexible tongue 30 ismade with moulding preferably injection moulding. Any type of polymermaterials could be used such as PA (nylon), POM, PC, PP, PET or PE orsimilar having the properties described above in the differentembodiments. These plastic materials could be reinforced with forinstance glass fibre, Kevlar fibre, carbon fibre or talk or chalk. Apreferred material is glass fibre, preferably extra-long, reinforced PPor POM.

FIGS. 7c-e show different embodiments made by injection moulding. Withthis production method a wide variety of complex three-dimensionalshapes could be produced at low cost and the flexible tongues 30 couldeasily be connected to each other to form tongue blanks 50. Of coursethe flexible tongue 30 could be made from metal. FIG. 7e shows that theflexible tongue could be made of an extruded or machined plasticsection, which could be further shaped with for example punching to forma flexible tongue according to the invention. Materials such as plastic,metals preferably aluminium, solid wood, wood based sheet material suchas HDF and compact laminate could be used.

FIG. 7f shows an embodiment, which consist of two sections 38 and 39,which are connected to each other. This will be explained more inconnection to FIGS. 16d -f.

In general any shape which allows that a part of the tongue could bendin length direction and spring back in such a way that the projectingportion could be displaced with 0.1 mm or more, will be possible to use.Normally the displacement should be 1-3 mm but very small displacementsof some 0.1 mm could be enough to form a vertical locking which preventsvertical movement especially in HDF material.

FIGS. 8a-8d show schematically a production method to fix the flexibletongue to the displacement groove. In this embodiment the flexibletongue is mechanically fixed. Of course glue or mechanical devices canalso be used. To simplify the understanding the panel 1′ is located withits front side up. The panel could also be turned with the rear side up.The tongue blanks 50 are moved through a separation unit 51, whichseparates the flexible tongue 30 from the tongue blank 50. The flexibletongue 30 could then be moved to a lower level with a vertical device55. This motion could also be combined with the separation. A pusher 54moves the flexible tongue 30 into the displacement groove 40 and fixesit with the friction connection 36. The flexible tongue is guided overthe strip 6 between an upper 52 and lower 53 guiding devices. Vacuumcould also be used to connect the flexible tongue 30 to the upper 52guiding device during the horizontal displacement into the displacementgroove 40. A lot of alternatives are possible within the main principlesthat the flexible tongue is separated from a tongue blank containing atleast two connected flexible tongues and displaced essentially parallelto its width and/or length into the displacement groove 40 where it isfixed with a friction force.

FIGS. 9a-d show schematically an alternative production method tomechanically fix the flexible tongue to the displacement groove. Thetongue blanks 50 are moved through a separation unit 51, which separatesthe flexible tongue 30 from the tongue blank 50. The flexible tongue 30is in this embodiment positioned using a fan wheel 58. The fan wheelprovides a safe handling of the flexible tongues. A pusher 54 moves theflexible tongue 30, via a tongue-guiding device, into the displacementgroove 40 and fixes it with the friction connection 36. The flexibletongue is guided over the strip 6 between an upper 52 and lower 53guiding devices.

FIGS. 10a-e show schematically a further production method tomechanically fix the flexible tongue to the displacement groove.Separates tongues are stored in a vertical magazine 59 and the outermosttongue is fed in the horizontal direction by a feeding device to avertical device 55. The tongue is fed between an upper horizontalfeeding means 65 and a lower horizontal feeding means to the verticaldevice 55, which lower the tongue. In this embodiment the lower feedingmeans is also a pusher. A pusher 54 moves the flexible tongue 30, via atongue-guiding device, into the displacement groove 40 and fixes it withthe friction connection 36. The flexible tongue is guided over the strip6 between an upper 52 and lower 53 guiding devices.

FIGS. 11a-c show schematically a tongue-fixing device, which uses afixing wheel 61. The tongue is fed in a feeding device 67 and a pusher54 pushes an end of the tongue preferably provided with a frictionconnection 36 into the displacement groove of the floor panel. Arelative motion between the panel and the fixing wheel 61, causes agradually fixing of the whole tongue into the displacement groove, asthe panel 1′ passes the fixing wheel 61. An alternative embodimentcomprising two or more wheels, gradually fixing the tongue.

FIGS. 12a-c show schematically an alternative tongue-fixing device,which in the same process fixes two tongues. In this embodiment thefixing device comprising two feeding devices and pushers and one fixingwheel, but alternative the fixing device comprising additional fixingwheels, pushers and feeding devices.

FIGS. 13a to 13f are examples which show that all known locking systemscould be adjusted to vertical folding with a flexible tongue 30according to the invention and that the flexible tongue 30 could beattached optionally to the strip or fold panel. In the embodiment ofFIG. 13e , the strip 6 is not rigid enough to form a vertical contactsurface. This could be solved by a tongue 10 and a groove 9 above theflexible tongue 3 30. Of course the vertical contact surface 6′ could bea part of the tongue groove and the vertical locking surface 24 could bethe projecting portion of the tongue as shown in FIG. 13 e.

FIGS. 14a-b show how a locking system could be designed to lock longside 4 a to long side 4 b with angling, short side 5 a to short side 5 bby vertical folding and/or angling and short side to long side withvertical folding or angling. FIGS. 14c-14d show how two panels A and Bwith mirror inverted locking systems could be locked to a floor with anadvanced installation pattern. Panels 1-6 could be installed withangling. Panel 7 could be installed by angling the short side to thelong side of pane 6. Panels 8-9 could be installed by angling. Panel 12is installed by angling the short side. Panels 13-23 are installed byfolding. Panels 24-26 are installed by angling and panels 27-34 byfolding. Thanks to the flexible tongue 30 on the short side the wholefloor could be installed with a simple angling action in spite of thefact that all panels are connected on all sides vertically andhorizontally and all panels are connected long to long side and long toshort side. This installation method could be used in connection withall types of flexible tongues and not only those embodiments that bendalong the length direction. FIG. 14b show that the locking system couldbe locked with a pressure force F caused by the flexible tongue 30.

FIGS. 15a-15d show how A and B panels with a flexible tongue could beinstalled and locked vertically D1 and horizontally D2 in a single ordouble herringbone pattern with only a simple angling action.

FIGS. 16a-c show vertical folding installation with square panels. Theflexible tongue 30 has several protruding parts P2. This embodimentcould be used as an alternative to several separate flexible tongueswhen the length of the joint edge exceeds for example 200 mm. Thefriction connection 36 could be located for example in a middle section.

FIGS. 16d-e show an alternative way to displace the flexible tongue. Themethod could be combined with a flexible tongue according to FIG. 7f .The new panel 1′ is in angled position with an upper part of the jointedge in contact with the first panel 1″ in the first row. The firstpanel 1′, the fold panel, is than displaced towards the second panel 1until the edges are essentially in contact and a part of the flexibletongue 30 is pressed into the displacement groove 40 as can be seen inthe FIG. 16e . The new panel 1′ is than folded down towards the secondpanel 1. FIG. 16f show that the tongue could be on the folding panel.Since the displacement of the new panel 1′ presses an edge section ofthe flexible tongue 30 into the displacement groove 40, vertical foldingwill be possible to make with less resistance. Such an installationcould be made with a flexible tongue that has a straight protrudingpart. The flexible tongue 30 does not have to bend in the lengthdirection if it has a flexible device such as rubber that could becompressed. The bending could be replaced by a horizontal turning actionwhere one edge section of the flexible tongue during locking is closerto the bottom 44 of the displacement groove 40 than another oppositeedge section.

FIGS. 17a-d show how a known locking system, used in large volumes onthe marked, could be converted to a vertical folding, preferably in twosteps. The first step is to replace the traditional tongue 10 with aflexible tongue 30. In this embodiment the locking systems will becompatible which means that an old and new panel could be locked to eachother. The tongues could be fixed to either the fold panel (see FIG. 17c) or the strip panel (see FIG. 17 d). After a while when all products inthe shops are sold, the groove 9 of the strip part could be adjusted.

Within the invention a lot of alternatives are possible to accomplishvertical folding with a flexible tongue.

A flexible tongue could be produced according to the same principle asknown mechanical devices, which create a spring effect similar tolocking devices used in doors, windows, furniture, cars and mobilephones. The flexible tongue with these mechanical devices could beformed with dimensions suitable for 6-15 mm floorings, especially woodfloorings, and inserted into the edge. FIG. 18 shows that the flexibletongue (30) could for example be mounted in a separate sliding section56 made of plastic or metal or any other suitable material andcontaining a compressible or flexible rubber, metal or plastic component(57) or similar able to create the spring effect. This sliding section56 could be connected into the edge of the floor panel in a holdinggroove 40′ which in this embodiment is rounded and has a shape similarto a part of a rotating saw blade. Since the holding groove 40′ only isformed in a part of the short side edge, it could be made rather deepand the edge will still have sufficient strength. A preferable featureof this embodiment is that the deepest part of the holding groove 40′ isonly located in a part of the edge. Contrary to the other embodimentsthe holding groove 40′ is not parallel with the joint edge and does notcover the whole edge. Of course other shapes are possible and theparallel groove is not excluded.

Especially on long and wide floor panels rather complicated devicescould be used since only 2-4 pieces are required per m2 of flooring.Even with a rather high unit price, the advantages with vertical foldingare considerable and could overcome a rather high cost for the lockingsystem. Due to the fact that the short sides are not sawn very often,metal components could also be used and these components could be formedin such a way that they are easy to remove from the floor panel if theshort side edge must be sawn.

In floor panels with a width of about 20 cm a flexible tongue with alength of a few cm is enough if it is positioned in the middle part ofthe short side about 6-9 cm from the corner section.

The flexible tongue could also be made of one single component asdescribed in the embodiment above and with a thickness of about 1 mmonly and could be used to connect floorboards with a thickness down to 4mm. A locking system with the flexible tongue, according to theinventions, is also very suitable for connecting thicker floorboards orabout 10-15 mm, especially wood and laminate floorboards. Thedisplacement groove 33 and/or the tongue groove 20, could be formed inseparate materials, which are connected as an edge portion to the core.In engineered wood floors, with for instance a lamella core, the edgeportion could be made of e.g. HDF, plywood, plastic or special hardwood, which are stronger than the core material. This separate edgeportion could be fixed between the top layer and the balancing layer.

Al features of the embodiment described above could be combined witheach other or used separately. The flexible tongues could be combinedwith all shown displacement or holding grooves. The locking systemscould be used in any shown joint or floor panel. The system according toFIG. 18 could for example be used in floor panels described in FIGS.14a-d . The tongue as shown in FIG. 7f could also have a shape as shownin FIG. 7b and it could be made to bend in the length direction wherethis bending is partly supported by a flexible material 38. The lockingstrips could in all embodiments be made of a separate material or in onepiece. Part of the strip 6 in FIG. 18 could be removed under the plasticcomponent 56 to facilitate fixing to the joint.

FIGS. 18a-c show different shapes of the flexible tongue. FIG. 18a showsone embodiment with an essentially sine shaped tongue, comprising twoperiods, and straight parts at the down periods and at the top periods.Second and third embodiments comprising two periods with differentlengths of the top periods. A fourth embodiment comprising one periodand a fifth embodiment comprising one period involving an asymmetric topperiod. The different lengths of the periods and asymmetry is used tofacilitate the connection, and lower resistance. FIG. 18b shows anembodiment before the ingates are removed and with recesses 66 at theinner part, which increase the flexibility of the tongue. FIG. 18c showsan embodiment with different radius at the inner part R3, at the bevelR2 and at the outer part R1. The figure shows that the total width TW ofthe tongue could vary between a position when the panel is not connectedTWS and a position when the panel is connected TWE. In the connectedposition is in this embodiment the tongue slightly compressed andpretensioned and therefore also shows a different shape. In anembodiment without the straight part at the top period of the sineshaped tongue it is possible to create a higher degree of pretension, atleast initially after installation, in the connected position, whichmight be an advantage. After a while the pretension might decrease.FIGS. 18d-f show embodiments to solve the problem which occur when thepanel is split. In one embodiment the tongue is replaced by anothertongue (see FIGS. 18d and f ), which is shorter. In another embodiment(see FIG. 18e ) the shape of the tongue is adopted so that the tonguecould be cut and still work.

FIGS. 19a-b show an embodiment of the tongue with indentations 63, ofdifferent shapes. The indentation counteracts the effect of shrinkage bymoulding, and could also be useful to help orientation of the tongue,when handling the tongue in connection with fixing. The bottom of thetongue is a suitable place for identification text or contact surface ofa pusher (e.g. when removing the tongue from a mould), since it doesn'tchange the sliding/displacing characteristics of the tongue. FIG. 19 dshows how different sizes of the tongue, due to production tolerances,could be compensated by a bevel at the lower displacement surface 64 ofthe tongue and an inclined tongue locking surface of the tongue groove22.

FIGS. 20a-d illustrate that various types, lengths and numbers oftongues could be combined and fixed to one displacement groove. Anadvantage is that different combination could be used to createdifferent strength and characteristics of the locking system, whichcould be adapted to different types of panels. A use of several tonguescould also replace product (panel) specific lengths of the tongues.

FIGS. 21a-d illustrate embodiments with non-continuous displacinggrooves. The non-continuous displacing groove could be processed by ajumping head 69 or created by inserting a filler 67 or inserting andfastening, e.g. by friction or gluing, of a divider 68.

FIGS. 22a-c illustrate embodiments of a tongue blank, straight orcircular and with ingates at one or both ends of the tongue. The tonguecould also be handled separately according to FIG. 22 d.

FIGS. 23a-g show different embodiments of a mechanical locking system incombination with a flexing tongue. FIGS. 23a and 23b show one embodimentof the same panel at the short side 23 a and at the long side 23 b. FIG.23c shows an embodiment, which is not possible to take up with angling.FIGS. 23a-d show an embodiment of a displacing groove with an inclinedupper displacing groove surface, which counteract the effect of humidityrelated shrinking and swelling of the panel and reduces the risk ofjamming of the tongue.

FIGS. 24a-g show embodiments of a tool 100-103 to be used when taking uppanels with the flexible tongue. The tool comprising a handle part 104and a tool part 105, which is adapted to be inserted in the tonguegroove or the displacement groove of a panel. In one embodiment thetongue is compressed when the tool 100 is inserted and pushed out of thetongue groove. In another embodiment (FIGS. 24d-e ) the tool part 103comprising a protrusion or recess 106 at the one end of the tool, whichis adapted to catch an end of the tongue, preferably provided with arecess or protrusion. This embodiment pulls out the tongue.

In order to increase the accessibility the tool might also comprise acurved part and/or produced of an elastic material, e.g. elasticbendable plastic or metal.

An alternative, for which a tool not is necessary (FIG. 24e ), is thatthe tongue has an end part, outside the displacement and tongue groove,such that it is visible when the panels are connected. The end part isadapted to be easy to grab and used when pulling out the tongue.

A floor panel with a flexible tongue could also be taken up using theconventional methods adapted to taking up floor panels with aconventional non-flexible tongue, e.g. angling-angling, angling-sliding,snapping-sliding or snapping-angling.

The method to produce a separate tongue, which is inserted into agroove, could of course be used to save material and improve frictionproperties even if the tongue is not flexible or displaceable. Themethods and principle could also be used together with a flexible tonguethat could be bent in vertical direction up and/or down during locking.Extruded V- or U-shaped sections, where an outer or inner part isflexible and which could cause at least a part of the section to moveessentially horizontally during the vertical folding could also be usedto lock floorboards in a vertical direction, according to the same basicprincipal as the above described flexible tongue.

The system could be used to connect tile shaped panes installed on awall and. The tile could be connected to each other and to a lockingmember fixed to the wall.

The flexible tongue according to the invention may be used without thelocking strip to accomplish vertical locking only.

It will be apparent to those skilled in the art that variousmodifications and variations of the present invention can be madewithout departing from the spirit and scope of the invention. Thus, itis intended that the present invention include the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

The invention claimed is:
 1. A set of building panels with a tonguebeing received in a sidewardly open groove of a first building panel,wherein the tongue, which is of an elongated shape, is configured tolock into a tongue groove of an adjacent second building panel, whereinthe tongue, when received in the sidewardly open groove, is bendable ina plane substantially parallel with a main plane of the first buildingpanel, such that the tongue is at least partially resilientlydisplaceable in said main plane, wherein the sidewardly open groove iscurved along a curve parallel to the main plane of the first buildingpanel, wherein a strip is configured to cooperate, in a connected state,with a downward open locking groove formed in the second building panel,which is adjacent the first building panel, wherein the tongue has agroove portion and a projecting portion, and wherein: in an unlockedposition of the tongue to the tongue groove, the groove portion islocated in the sidewardly open groove of the building panel and thetongue is entirely located outside the tongue groove; and in a connectedstate of the tongue to the tongue groove after locking, the grooveportion is located in the sidewardly open groove of the building paneland the projecting portion projects outside the sidewardly open grooveand into the tongue groove.
 2. The set of building panels as claimed inclaim 1, wherein the flexible tongue is made of moulded polymer materialand is reinforced with fibres.
 3. The set of building panels as claimedin claim 1, wherein the flexible tongue is made of moulded polymermaterial and is reinforced with glass fibres.
 4. The set of buildingpanels as claimed in claim 1, wherein the tongue comprises indentations.5. The set of building panels as claimed in claim 1, wherein aprotrusion is arranged at an upper displacement surface and/or at alower displacement surface of the tongue.
 6. The set of building panelsas claimed in claim 1, wherein the tongue comprises an end partconfigured to be easy to grab.